1.5-step moulding live on display

Nissei ASB Machine Co., Ltd. Hall C6 – Booth 541

Nissei ASB demonstrates the PF36 Series PET bottle moulding solution at 18,000 bph

Nissei ASB Machine Co., Ltd., a leading manufacturer of machines and moulds for injection stretch blow moulding of PET and other plastics, will demonstrate its PF36-Series 1.5-step moulding machine. Since the launch of the PF36 Series in Japan in 2020, over 60 systems have been delivered to leading beverage companies across the country. Now, ASB brings this proven solution to the global market.

Photo top: PF36/36-600 1.5-step PET injection stretch blow moulding machine, featuring ASB’s Vision 1 control and monitoring system

The PF36 Series is a family of PET injection stretch blow moulding machines that is claimed to combine the advantages of both 1-step and 2-step PET bottle moulding into one machine, hence the term “1.5-step Moulding”. The Series is claimed to be highly suitable for short supply chain versus centralised mass production. By locating smaller production facilities closer to the point of sale, transportation costs are significantly reduced, says Nissei ASB. With flexible production systems in place, the user can adjust output in real time based on actual demand – reducing waste and lowering inventory costs. Shorter shipping routes lead to lower fuel consumption, reduced logistics expenses, faster delivery times, and a more responsive supply chain.

Live moulding at the booth

ASB’s exhibition booth will feature live moulding of the highest output model from its PF36 Series line-up, the PF36/36-600. The displayed model is configured with 36 cavities at the preform injection station while the blow station has 12 cavities, capable of moulding bottles up to 600 ml capacity.

Bottles can be blown much faster than preforms can be injected. By designing the PF36 Series with this 3:1 ratio, each section of the machine is utilised at maximum efficiency, enabling shorter cycle times and contributing to reduced operating costs, making the PF36 Series an attractive investment for high-output PET bottle production, says Nissei ASB.

Capable of moulding up to 18,000 bph, the machine’s compact size, and having no requirement for preform storage or handling systems, mean that, based on in-house research conducted by Nissei ASB, only 1/3rd of the floor space is required when compared to an equivalent output 2-step bottle moulding system.

By installing multiple units over time, owners are able to scale up their production capacity in line with growing demand, and running multiple machines allows greater flexibility of production planning, mould change-overs and planned maintenance without stopping the entire line. Additionally, using residual heat in the preform from the injection station, a feature of the 1.5-step moulding process, energy consumption for moulding can be as much as 20% lower compared to an equivalent 2-step moulding system, says Nissei ASB. Because the system moulds its own preforms, it is claimed to achieve consistent product quality and to avoid disruptions that could result from receiving defective or damaged preforms from external suppliers.

In line with circular-economy trends, and as will be demonstrated during live moulding, the PF36/36-600 is capable of moulding bottles using 100% rPET material without compromising speed or product quality.

Machine actuation systems are a full hybrid combination of hydraulics, pneumatics and multiple servo motor systems – each system being selected to perform specific functions with good efficiency. Machine control and monitoring is via ASB’s Vision1 system, a proprietary software and hardware package that is compliant with the OPC UA global standard protocol for industrial network communication offering a host of possibilities, including networking into factory management software, integration of ancillary equipment control and monitoring, global accessibility to production data and remote off-site diagnosis by factory technical staff.

The moulding machine will be demonstrated at drinktec together with a range of matched upstream and downstream ancillary equipment including chiller, resin dryer, mould temperature controller, mould dehumidifier, conveyor systems, etc.

ASB’s booth will also be showcasing a range of new developments and packaging technologies including: through-hole handle moulding, zero cooling, returnable & refillable, lightweight collapsible water servers, canted/tilted neck bottles, PET cans, and more.

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